12241

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)

Page 1 of 13
Winter Examination - 2012
Subject Code:- 12241 Model Answer

Q.1.
a) When component is subjected to stress for long period of time at higher temperature it
deforms slowly and progressively. This phenomenon is called as creep. 2
b) When the component is subjected to variable stress (both in magnitude and direction) its
failure occurs earlier. This failure is known as fatigue failure. 2
c) Applications of knuckle joint.
i) To connect tractor and trolley. 1
ii) Tie rod joint of roof truss. 1
d) i) Spring rate is the load required to produce unit deflection. 1
ii) Spring index is ratio of mean coil diameter of spring. 1
e) i) Maximum shear stress theory. 1
ii) Maximum principal stress theory. 1
f) Stress strain diagram for M.S.

g) ACME thread, square thread are used in power screws. 2
h) Ergonomics is branch of engineering science which deals with study of man-machine
working environment relationship and application of anatomical, physiological and
psychological principles to solve the problems arising from this relationship. 2

i) Classification of bearing. 2

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Page 2 of 13
Bearing life is expressed in total no. of revaluations or number of hours at a given constant
speed which bearing can complete before first evidence of fatigue failure developed on balls or
races. Since identical bearing working under same condition may have different life. Therefore
life of bearing is expressed as rating life. Rating life is number of revolutions or number of hours
at given constant speed that 90% of group of bearing will complete before evidence of first
fatigue failure. 2
j) advantages of screwed joints. 2x1
i) Assembly and dismantling is easy.
ii) Gives higher clamping force.
k) Pre-requisites of good coupling. x4=2
i) It should transfer full power from one shaft to other.
ii) It should keep shafts in aligned condition.
iii) It should not have any projected parts.
iv) It should be easy to connect and disconnect.
l) Functions of shaft coupling. 2x1=2
i) To connect the two shafts of two different units.
ii) Provide mechanical flexibility between two shafts.
m) Key is mechanical element which is fitted between shaft and hub to avoid slipping. 1
The function of key is to avoid relative motion between shaft and hub. 1

Q.2.
a) Failures to be considered in knuckle joint subjected to tensile load P.
i) Failure of rod in tension.

2
4
d t P
t
o =

ii) Failure of pin in shear

2
1
4
2 d P
t
t =
t: allowable shear stress

iii) Failure of pin in bending.

|
.
|
\
|
+ =
4 3 2
) . (
1
t t P
M B M

3
1
32
d
M
t
o =

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Page 3 of 13

iv) Failure of single eye in shearing.
( ) t t d d P
1 2
=

v) Failure of single eye in tension.
( )t d d t P
1 2
= o

vi) Failure of single eye in crushing.
cr t d P o
1
=

vii) Failure of fork end in shear.
( ) t
1 1 2
2 t d d P =

viii) Failure of fork end in tension.
( ) t t d d P o
1 1 2
2 =

ix) Failure of fork end in crashing.
cr t d P o
1 1
2 =

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Page 4 of 13
b) The stress in any loaded component is always kept lower than ultimate stress. This stress is
known as working or design stress. Thus design or working stress is always lower than
ultimate stress. The factor of safety is defined as ratio of maximum stress to working stress.
ductile material
stress Working
stress Yield
S O F = . . .
brittle material
stress Working
stress Ultimate
S O F = . . 2
Following are the factors which govern the factor of safety. 6
i) The extent of loss of life it failure occurs.
ii) The extent of loss of property if failure occurs.
iii) The reliability of properties of material.
iv) The extent of assumption made in design process.
v) The reliability of applied load.
vi) The extent of stress concentration.
c) i) Aesthetic consideration in design regarding shape and colour.
1) The colour and shape of component should be such that in should attract appeal and
impress customer. 1
2) The shape should not be like blocks but various forms like sculpture, streamlined,
aerodynamic, taper should be used. 1
3) The component should be symmetrical at lean about one axis. 1
4) The colour should match with conventions, moods e.g. red for danger, gray for dull,
yellow for cautions, green for safe etc. 1

ii) Procedure for selection of bearing from manufacturers catalogue. 4
1) Calculate radial and axial forces and determine diagram of shaft.
2) Select proper type of bearing.
3) Start with extra light series for given diagram go by trial of error method.
4) Find value of basic static capacity (co) of selected bearing from catalogue.
5) Calculate ratios Fa/VFr and Fa/Co.
6) Calculate values of radial and thurn factors.
(X & Y) from catalogue.
7) For given application find value of load factor Ka from catalogue.
8) Calculate equivalent dynamic load using relation.
Pe = (XVFr + YF
A
) Ka.
9) Decide expected life of bearing considering application. Express life in million revolutions
L
10
.
10) Calculate required basic dynamic capacity for bearing by relation.
11) Check whether selected bearing has req. dynamic capacity, it not select the bearing of
next series and repeat procedure from step-4.
Q.3.
a) P = 25 KN = 25 x 10
3
N
b = 3t
e = 140 mm
o = 100 N/mm
2

Direct tensile stress
2
3
25000
t bt
P
= = 2
Bending moment due to force
M = P x e 1

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Page 5 of 13
Bending stress y
I
M
b
= = o 1

( )
3
2 2
3
9
140 25000 6
3
140 25000 6 140 25000 6
2
12
1
140 25000
t
t t b t
b
b t
b

=

=

=
= o

Total tensile stress = bearing stress + Direct stress
Total tensile stress
2 3
3
25000
9
140 25000 6
t t
+

= 2
3
2 3
9 100 3 25000 140 25000 6
100
3
25000
9
140 25000 6
t t
t t
= +
= +

By dividing 900 to both the sider.
23333.3 + 83.3 t = t
3

t
3
83.3 t = 23333
By trial and error
t = 30 mm; b = 90 mm 1

b)

Dia. of sleeve
By imperical relation the outer dia of sleeve can be fixed as 2d = 110 mm. Let us check
the shear stress induced in sleeve.
1
mm say mm d
T
d
d
T
shaft of Design
mm N
m N
N
P
T
mm N
mm N
m p r N
W KW P
muff
55 53
60
10 81 . 1 16 16
16
. 10 81 . 1
10
200 2
10 38 60
. .
200 2
10 38 60
2
60
/ 10
/ 60
. . . 200
10 38 38
6
3
3
6
3
3
3
2
2
3
=

=
=
=
=

=

=
=
=
=
=
= =
t t t
t
t
t
t t
t
t
2
2

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Page 6 of 13
( )
( ) ( ) ( )
( )
2
3
6
4 3
6
4 3
/ 38 . 7 16
15 110
10 81 . 1 16
5 . 0 1 110
10 81 . 1 16
1
16
mm N
K D
T
=

=
=
t
t
t
t

Since induced shear stress in sleeve (7.38 N/mm
2
) is less than allowable shear stress
(10N/mm
2
), design is safe outer dia of sleeve can be fixed as D = 110 mm.
mm w
mm say
mm
d
key of width
key of Design
14
14
75 . 13
4
55
4
=
= = =

Considering failure of key in shear

mm say l
l
d
lw T
80 35 . 78
2
55
60 14 10 81 . 1
2
6
=
=
= t
2
length of key = 80mm.
c) Causes of stress concentration are as under.
i) Abrupt changes in cross-section like in keyway, steps, grooves, threaded holes resules in
stress concentration. 1
ii) Poor surface finish The surface irregularities is also one of the reason for stress
concentration. 1
iii) Localised loading Due to heavy load on small area the stress concentration occurs in
the vicinity of loaded area. 1
iv) Variation in material properties Particularly defects like internal flaws, voids, cracks, air
holes, cavities also results in stress concentration. 1
Following are two methods to reduce stress concentration.
1) Stress concentration in shafts having steps can be reduced by providing fillet instead of
step as shown below.

2

2) Stress concentration due to hole can be reduced by having two small holes as shown.

2
2

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Page 7 of 13
Q.4. Any TWO (2 x 8)
Direct shear load on each bolt
N
n
w
WS
3
3
10 10
4
10 40
=
= = 1
Maximum tensile load carried by bolts 3 & 4
( ) ( ) | | ( ) ( ) | |
2 2
3
2
2
2
1
575 600 2
575 600 10 40
2
2 .
+

=
+
=
L L
L WL
wt 1
N wt 95 . 9990
1381250
10 38 . 1
10
=
= 1
Equivalent tensile load
( ) ( )
(
+ + =
2 2
4
2
1
ws wt wt wte 1
( ) ( )
(
+ + =
2
3 2
10 10 4 95 . 999 95 . 9990
2
1
wte 1
N wte 80 . 16173 =
Equivalent tensile load (wte)
( ) t dc wte 6
4
2
=
t
1
mm dc
dc
15 . 17
70 ) ( 7854 . 0 80 . 16173
2
=
=
1
From table (coarse series), the standard core diameter is 18.933 mm and the corresponding
size of the bolt is M M22. 1
a) i) Mean diameter of the spring coil
Twisting moment on the spring
d
d D
W T 6875
2
5
2750
2
2
= = = 1
Twisting moment,
mm d
d d
d T
13 . 9
420
16
6875
16
3
3
=
=
=
t
t
t
1
From table, a standard wire of size SWG 3/0 having diameter (d) = 9.49mm.
Mean dia. of the spring coil, D = 5d = 5 x 9.49 = 47.45mm 1
Outer dia. of the spring coil D
0
= D + d = 47.45 + 9.49 = 56.94mm
Inner dia. of the spring coil Di = D d = 47.45 9.49 = 37.96mm
ii) No. of turns of the spring coil
Deflection of the spring

( )
10 5 . 9
63 . 0
49 . 9 10 84
5 500 8
6
8
3
3
3
say n
n
n
ad
n wc
=
=

=
= o

For square and ground ends, total no. of turns
n
1
= n + 2 = 10 + 2 = 12
iii) Free length of spring.

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Page 8 of 13
Maximum compression o max = mm 33 2750
500
6
= 1
Free length of the spring L
F
= n
1
d + o max + 0.15 o max
= 12 x 9.49 + 33 + 0.15 x 33
= 151.83 say 152mm 1
iv) Pitch of the coil.
73 . 13
1 12
152
1
1
=
=
n
LF
P say 13.8 mm
b) Design of screw spindle.
- First find the core dia. dc of screw by considering the screw under pure compression
( )
2
4
6 6 dc c AC c W
t
= =
The standard proportions of the square threaded screw are fixed from table. 1
- Find the torque (t) required to rotate the screw & find the shear stress (t) due to this torque
Torque required to lift the load
( )
2
tan
2
d
w
d
P | o t + = =
shear stress due to torque (t) 1
( )
3
16
dc t
t
t =
Also find direct compressive stress (6c) due to axial load
( )
2
4
6
dc
W
c
t
=
- Find the principal stresses
Maximum principal stress (tensile or compressive)
( ) ( ) ( )
2 2
4 6
2
1
2
6
max 6 t + + = c
c
c
and maximum shear stress
( )
2 2
4 6
2
1
max t t + = c 1
these stresses should be less than permissible stresses.
- Find the height of nut, considering the bearing pressure on the nut,
( ) ( ) | |n dc do
W
pb
2 2
4

=
t
1
where n = No threads in contact with screw spindle
Height of nut h = n x p, P = pitch of threads
- Check the stresses in screw & nut
( )
( ) 2 / ,
.
.
P t
t do n
W
nut
t dc n
W
screw
= =
=
t
t
t
t
1
- Find inner dia. (D
1
), outer dia. (D
2
) & thickness (t
1
) of the nut collar
Tearing strength of nut, ( ) ( ) | | t do D W 6
4
2 2
1
=
t

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Page 9 of 13
Crushing strength of the nut collar ( ) ( ) | | c D D W 6
4
2
1
2
2
=
t
1
Shear strength of the nut collar t t =
1 1
.t D W

2

a)The transverse fillet welds are designed for tensile strength.

1

Single transverse fillet weld double transverse fillet weld throat thickness t = S x sin 45
0
= 0.707
& minimum area of the weld or throat area
A = throat thickness x length of weld 1
= t x l = 0.707 s x l
Tensile strength of the joint for single fillet weld
P = Throat area x Allowable tensile
P = 0.7007 Sl x 6t 1
Tensile strength of the joint for double fillet weld
P = 2 x 0.707 S x l x 6t = 1.414 S x l x 6t 1
Strength of parallel fillet welded joints

1

Double parallel fillet weld Enlarged new of a fillet weld
Parallel fillet welded joints are designed for shear strength minimum area of weld or the throat
area A = 0.707 S x l 1
Shear strength of the joint for single parallel fillet weld
P = Throat area x Allowable shear stress = 0.707 S x l x C 1
& shear strength of the joint for double parallel fillet weld
P = 2 x 0.707 x S x l x t = 1.414 S x l x t 1

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Page 10 of 13
b) Mean diagram & the screw
d = do P/2 = 50 8/2 = 46mm 1
055 . 0
46
8
tan =
= =
t t
o
d
P

Angle for acme threads is 2| = 29
0
or | = 14.5
0

virtual coefficient of frication
155 . 0
5 . 14 cos
15 . 0
cos
tan
1 1
= = = =
|
Q 1
Force required to overcome friction at the screw
( )
N
w w P
530
155 . 0 055 . 0 1
155 . 0 055 . 0
2500
tan . tan 1
tan tan
tan
1
1
1
=
(

+
=
(
+
= + =
| o
| o
| o
1
and torque required to over come fiction at the screw T
1
= P x d/2 = 530 x 46/2 = 12190 N-mm 1
mean radians of collar, mm
R R
R 25 . 41
2
5 . 27 55
2
2 1
=
+
=
+
=
Assuming uniform wear, torque required to over come friction at collar
T
2
= 2 wR = 0.12 x 25000 x 41.25 = 12375 N-mm 1
Total torque required to overcome friction
T = T
1
+ T
2
= 12190 + 12375 = 24565 N-mm 1
Power required to drive the screw
kw
watts
N T
TW
077 . 0
77
60
30 2 24565
60
2
=
=

=
= =
t t
2
c) Torque transmitted by the shaft
mm N
m N
N
P
T
=
=
=
3
10 6 . 79
6 . 79
120 2
60 1000
2
60
t t
1
Torque transmitted T = (t - T
2
) x R
79.6 x 10
3
= (T
1
T
2
) x 100
T
1
T
2
= 796 N (i) 1
) ( 57 . 2
4098 . 0
3 . 2
9426 . 0
12
log
9426 . 0 3 . 0 log 3 . 2
2
1
2
1
ii
T
T
T
T
=
= =
|
.
|
\
|
= = =
|
|
.
|
\
|
t
t u

from equations (i) & (ii)
T
1
= 1303 N and T
2
= 507 N 1
Total vertical load on the pulley
W
T
= T
1
+ T
2
+ W = 1303 + 507 + 200 = 2010 N
Bending moment acting on the shaft
M = W
T
x L = 2010 x 300 = 603 x 10
3
N-mm 1

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Page 11 of 13
Equivalent twisting moment
( ) ( )
2 2
ktT M km T
e
+ = Assume km = 1.5 & kt = 2 1
( ) ( ) mm N = + =
3
2
3 2
10 918 10 6 . 79 2 603 5 . 1 1
mm say d
d d
d T
e
55 1 . 51
87 . 6 35
16
10 918
16
3 3 3
3
=
= =
=
t
t
t

a) t
t t n
b or
b
t n
4
3
12
3
3 =
= =
1
Effective length of the spring
2L = 2L
1
L = 1050 85 = 965 mm
L = 482 5 mm 1
No. of graduated leaves, n
G
= n n
F
= 12 2 = 10
Assuming that the leaves are not initially stressed
maximum stress or bending stress for full length leaves
( ) ( )
3
2 2
225476
280
2 3 10 2 4
5 . 482 2700 18
3 2
. 18
6
t
t t nf nG bt
L W
b
=
+

=
+
=

t = 9.3 say 10 mm 1
b = 4 t = 4 x 10 = 40 mm 1
Deflection of the spring
( )
( )
( )
) / 10 210 ( 7 . 16
2 3 10 2 10 40 10 210
5 . 482 2700 12
3 2
12
2 3
3 3
3
3
3
mm N E mm
nf n Ebt
wL
G
= =
+

=
+
=
o
o

1
1
1
1
1
1

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Page 12 of 13
b) i) The diameter of the shaft (d) is obtained by considering the shaft under pure torsion.
Twisting moment on the shaft T = P x L & resisting torque,
3
16
d T = t
t
1
From this relation, the dia. of the shaft (d) may be obtained.
ii) The diameter of the boss (d
2
) is taken as 1.6 d & the thickness of the boss (t
2
) as 0.3 d.
iii) The length of the boss (l
2
) may be taken from d to 1.25d. It may be checked for a trial
thickness t
2
by taking moments @ the axis. Equating. The twisting moment (P x L) to the
moment of resistance to tearing parallel to the axis.
( )
2 2
2
2
2 2
6
2
2
6
t d t t
L P
l
t d
t t L L P
+
=
|
.
|
\
| +
=

iv) The dia. of the shaft at the centre of the bearing (d
1
) is obtained by considering she shaft
is combined bending and twisting B.M. on the shaft M = P x L
& twisting moment, T = P x L. 1
( ) ( )
2 2 2 2
2 2
L l P L P l P T
T M T
e
e
+ = + =
+ =

( ) ( )
3
1
2 2 3
1
16 16
d L l P or d T
e
= + = t
t
t
t

The length l may be taken as 2 l 2.
From the above expression, the value of d
1
may be obtained.
v) The key for the shaft is designed as usual for transmitting a torque of P x l.
vi) The cross-section of the lever near the boss may be determined by considering the lever
in bending. It is assumed that the lever extends to the centre of the shaft which results in a
stronger section of the lever.
B.M. on the lever M = P x L 1
Section modulus
2
6
1
B t Z =
Bending stress
2
2
6
6
1
2
6
tB
PL
B t
L P M
b =
= = 1

1

1

1

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Page 13 of 13
c) i) Torque transmitted by the shaft
mm N T
m N
N
P
T
=
=
=
3
3
10 84 . 272
84 . 272
700 2
60 10 20
2
60
t t

Torque transmitted by the shaft
mm say d
d
d
d T
35 63 . 32
1 . 34739
40
16 10 84 . 272
16
3
3
3
3
=
=
=

=
t
t
t

ii) Pitch circle diameter of bolts D
1
= 3d = 3 x 35 = 105 mm 1
max. torque transmitted (Tmax)
( )
( )
mm d
mm d
d
D
n b d
25 . 5
57 . 27
2
105
6 40
4
10 84 . 272
2
1
4
10 84 . 272
1
2 2
1
2
1
3
2
1
3
=
=
=
=
t
t
t

Assuming coarse threads, the nearest standard size of bolt is M7.
iii) Thickness of flange t
f
= 0.5d = 0.5 x 35 = 17.5 mm 1
outer diameter of the flange D
2
= 4d = 4 x 35
= 140 mm
Thickness of the protective circumferential flange
t
p
= 0.25d = 0.25 x 35 = 8.75 say 10 mm 1

--------The End-------
1
1
1
1
1

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